Blower Assembly

ABSTRACT

An air handling unit has a blower assembly, a first interior zone, and a second interior zone and the blower assembly physically separates the first interior zone from the second interior zone. A method includes providing a cabinet configured to receive a blower assembly, inserting a blower assembly into the air duct, and closing a cabinet door of the cabinet, wherein upon closing the cabinet door, the primary air flow path from a location within the cabinet downstream of the blower assembly to a location within the cabinet upstream of the blower assembly is through a blower housing of the blower assembly. A blower assembly has a blower housing comprising at least one air inlet and at least one air outlet and a blower deck extending from the outlet, wherein the blower deck comprises at least one substantially flat component having a substantially orthogonal wall extending from the flat component.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

BACKGROUND

Heating, ventilation, and air conditioning systems (HVAC systems)sometimes comprise air handling units comprising blower assemblies thatattach to zone separation decks of the air handling units.

SUMMARY OF THE DISCLOSURE

In some embodiments, an air handling unit is provided that comprises ablower assembly, a first interior zone, and a second interior zone,wherein the blower assembly physically separates the first interior zonefrom the second interior zone.

In other embodiments, a method of creating air pressure zones in an airhandling unit is provided that comprises providing a cabinet configuredto receive a blower assembly, inserting a blower assembly into the airduct, and closing a cabinet door of the cabinet, wherein upon closingthe cabinet door, the primary air flow path from a location within thecabinet downstream of the blower assembly to a location within thecabinet upstream of the blower assembly is through a blower housing ofthe blower assembly.

In yet other embodiments, a blower assembly for an air handling unit ofan HVAC system is provided and the blower assembly comprises a blowerhousing comprising at least one air inlet and at least one air outletand a blower deck extending from the outlet, wherein the blower deckcomprises at least one substantially flat component having asubstantially orthogonal wall extending from the flat component.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and theadvantages thereof, reference is now made to the following briefdescription, taken in connection with the accompanying drawings anddetailed description, wherein like reference numerals represent likeparts.

FIG. 1 is an oblique view of an air handling unit according toembodiments of the disclosure;

FIG. 2 is an orthogonal view of the front of the air handling unit ofFIG. 1;

FIG. 3 is a partially exploded oblique view of the air handling unit ofFIG. 1;

FIG. 4 is a simplified oblique view of the air handling unit of FIG. 1showing a plurality of inner shell components encased within outerskins;

FIG. 5 is an oblique left side view of the heat exchanger cabinet rightshell of FIG. 1;

FIG. 6 is an oblique left side view of the blower cabinet right shell ofFIG. 1;

FIG. 7 is an oblique view of a blower assembly of FIG. 2 from afront-upper-right viewpoint;

FIG. 8 is an orthogonal front view of the blower assembly of FIG. 2;

FIG. 9 is an orthogonal rear view of the blower assembly of FIG. 2;

FIG. 10 is an orthogonal top view of the blower assembly of FIG. 2;

FIG. 11 is an orthogonal bottom view of the blower assembly of FIG. 2;

FIG. 12 is an orthogonal right side view of the blower assembly of FIG.2;

FIG. 13 is a partial cross-sectional orthogonal right side view of theblower assembly of FIG. 2;

FIG. 14 is an oblique partial view of the blower assembly of FIG. 2 froma rear-upper-right viewpoint; and

FIG. 15 is an oblique partial exploded view of the blower assembly ofFIG. 2 from a rear-lower-right viewpoint.

DETAILED DESCRIPTION

Interior walls of some air handling units may be planar in construction,covered with insulation that may release particulate matter, and may beconfigured to carry a plurality of brackets for carrying removablecomponents of the air handling units. The removable components of suchair handling units may need to be rearranged to configure the airhandling unit for use in a particular installation configuration withrespect to the direction of gravity. For example, a removable drain panmay need to be relocated within the air handling unit for use in aparticular installation configuration. Still further, construction ofthe air handling units may be time consuming and/or difficult due to aneed to install a variety of brackets and/or support structures to theinterior walls of the air handling units. Further, removal and/orreplacement of the removable components of some current air handlingunits may be unnecessarily difficult due to complicated multi-piecemounting brackets and supports.

Accordingly, the present disclosure provides, among other features, anair handling unit (AHU) that comprises interior cabinet walls shapedand/or otherwise configured to selectively carry removable components ofthe AHU with a reduced need for brackets and supports. The interiorcabinet walls of the AHU of the present disclosure may be further shapedand/or otherwise configured to reduce or eliminate the need to rearrangecomponents within the AHU to configure the AHU for a selectedinstallation orientation relative to the direction of gravity. In someembodiments, an AHU of the disclosure may comprise interior cabinetwalls that are formed and/or shaped to integrally comprise bracketsand/or other mounting features for carrying removable components. Insome embodiments, an AHU may comprise integral drain pans, the integraldrain pans being suitable for use in different installation orientationswith respect to the direction of gravity.

AHUs of some HVAC systems comprise blower assemblies that attach to zoneseparation decks installed in the blower cabinet portion of the AHUs. Insome cases, the zone separation decks are structurally inadequate toprevent significant amounts of vibration, stress cracks, and/or othermechanical failures due to the deck carrying heavy blower assemblies. Insome cases, the zone separation decks may be formed as a substantiallyplanar component having a hole shaped and/or sized to accommodateconnection to an output of the blower assembly. In some cases, the holein the planar component is located well within the entrance to theblower assemblies so that installation and removal of a blower assemblyrequires reaching far into the blower cabinet while simultaneouslyattempting to align features of the blower assembly with complementaryfeatures of the deck.

Accordingly, the present disclosure, in some embodiments, providessystems and methods for providing and/or installing blower assemblieswithout the need to carefully manage the position of a heavy blowerassembly while installing it into an AHU. In some embodiments, thepresent disclosure provides a blower assembly comprising an integralblower deck. In some embodiments, the integral blower deck may easily bereceived into an AHU by sliding edges of the integral blower deck intomounting channels of the AHU. In some embodiments, the mounting channelsof the AHU may be located along the interior walls of the AHU. In someembodiments, the mounting channels may be integral with the interiorwalls of the AHU.

Referring now to FIGS. 1-3, an AHU 100 according to the disclosure isshown. In this embodiment, AHU 100 comprises a lower blower cabinet 102attached to an upper heat exchanger cabinet 104. Most generally and forpurposes of this discussion, AHU 100 may be described as comprising atop side 106, a bottom side 108, a front side 110, a back side 112, aleft side 114, and a right side 116. Such directional descriptions aremeant to assist the reader in understanding the physical orientation ofthe various components parts of the AHU 100 but that such directionaldescriptions shall not be interpreted as limitations to the possibleinstallation orientations of an AHU 100. Further, the above-listeddirectional descriptions may be shown and/or labeled in the figures byattachment to various component parts of the AHU 100. Attachment ofdirectional descriptions at different locations or two differentcomponents of AHU 100 shall not be interpreted as indicating absolutelocations of directional limits of the AHU 100, but rather, that aplurality of shown and/or labeled directional descriptions in a singleFigure shall provide general directional orientation to the reader sothat directionality may be easily followed amongst various Figures.Still further, the component parts and/or assemblies of the AHU 100 maybe described below as generally having top, bottom, front, back, left,and right sides which should be understood as being consistent inorientation with the top side 106, bottom side 108, front side 110, backside 112, left side 114, and right side 116 of the AHU 100.

Blower cabinet 102 comprises a four-walled fluid duct that accepts fluid(air) in through an open bottom side of the blower cabinet 102 andallows exit of fluid through an open top side of the blower cabinet 102.In this embodiment, the exterior of the blower cabinet 102 comprises ablower cabinet outer skin 118 and a blower cabinet panel 120. The blowercabinet panel 120 is removable from the remainder of the blower cabinet102 thereby allowing access to an interior of the blower cabinet 102.Similarly, heat exchanger cabinet 104 comprises a four-walled fluid ductthat accepts fluid (air) from the blower cabinet 102 and passes thefluid from an open bottom side of the heat exchanger cabinet 104 andallows exit of the fluid through an open top side of the heat exchangercabinet 104. In this embodiment, the exterior of the heat exchangercabinet 104 comprises a heat exchanger cabinet outer skin 122 and a heatexchanger cabinet panel 124. The heat exchanger cabinet panel 124 isremovable from the remainder of the heat exchanger cabinet 104 therebyallowing access to an interior of the heat exchanger cabinet 104.

The AHU 100 further comprises a plurality of selectively removablecomponents. More specifically, the AHU 100 comprises a heater assembly126 and may be removably carried within the heat exchanger cabinet 104.The AHU 100 further comprises a refrigeration coil assembly 128 that mayalso be removably carried within the heat exchanger cabinet 104. In thisembodiment, the heater assembly 126 is configured to be optionallycarried within heat exchanger cabinet 104 nearer the top side 106 of theAHU 100 than the refrigeration coil assembly 128. Similarly, the AHU 100comprises a blower assembly 130 that may be removably carried within theblower cabinet 102. The AHU 100 may be considered fully assembled whenthe blower assembly 130 is carried within the blower cabinet 102, eachof the refrigeration coil assembly 128 and the heater assembly 126 arecarried within the heat exchanger cabinet 104, and when the blowercabinet panel 120 and heat exchanger cabinet panel 124 are suitablyassociated with the blower cabinet outer skin 118 and the heat exchangercabinet outer skin 122, respectively. When the AHU 100 is fullyassembled, fluid (air) may generally follow a path through the AHU 100along which the fluid enters through the bottom side 108 of the AHU 100,successively encounters the blower assembly 130, the refrigeration coilassembly 128, and the heater assembly 126, and thereafter exits the AHU100 through the top side 106 of the AHU 100.

In this embodiment, each of the four walls of the blower cabinet 102 andthe heat exchanger cabinet 104 are configured to have a double-wallconstruction. More specifically, the heat exchanger cabinet 104 furthercomprises a heat exchanger cabinet right shell 132 and a heat exchangercabinet left shell 134. In this embodiment, the heat exchanger cabinetright shell 132 and the heat exchanger cabinet left shell 134 may bejoined to generally form the interior of the heat exchanger cabinet 104.In order to form the above-mentioned double-wall construction for theheat exchanger cabinet 104, the heat exchanger cabinet outer skin 122generally covers the right side and back side of the heat exchangercabinet right shell 132 while also generally covering the left side andback side of the heat exchanger cabinet left shell 134. Most generally,the heat exchanger cabinet right shell 132, the heat exchanger cabinetleft shell 134, and the heat exchanger cabinet outer skin 122 are shapedso that upon their assembly together a heat exchanger cabinet wall spaceexists between the heat exchanger cabinet outer skin 122 and each of theheat exchanger cabinet right shell 132 and the heat exchanger cabinetleft shell 134. The blower cabinet right shell 136, the blower cabinetleft shell 138, and the blower cabinet outer skin 118 are also shaped sothat upon their assembly together a blower cabinet wall space existsbetween the blower cabinet outer skin 118 and each of the blower cabinetright shell 136 and the blower cabinet left shell 138.

In some embodiments, one or more of the heat exchanger cabinet wallspace and blower cabinet wall space may be at least partially filledwith an insulating material. More specifically, in some embodiments, apolyurethane foam may at least partially fill exchanger cabinet wallspace and the lower cabinet wall space. At least partially filling oneor more of the spaces may increase a structural integrity of the AHU100, may increase a thermal resistance of the AHU 100 between theinterior of the AHU 100 and the exterior of the AHU 100, may decreaseair leakage from the AHU 100, and may reduce and/or eliminate theintroduction of volatile organic compounds (VOCs) into breathing airattributable to the AHU 100. Such a reduction in VOC emission by the AHU100 may be attributable to the lack of and/or reduced use of traditionalfiberglass insulation within the AHU 100 made possible by the insulativeproperties provided by the polyurethane foam within the spaces.

In some embodiments, each of the blower cabinet outer skin 118 and theheat exchanger cabinet outer skin 122 may be constructed of metal and/orplastic. Each of the heat exchanger cabinet right shell 132, the heatexchanger cabinet left shell 134, blower cabinet right shell 136, andblower cabinet left shell 138 may be constructed of a sheet moldingcompound (SMC). The SMC may be chosen for its ability to meet theprimary requirements of equipment and/or safety certificationorganizations and/or its relatively rigid cleanable surfaces that areresistant to mold growth and compatible with the use of antimicrobialcleaners. Further, the polyurethane foam used to fill the spaces maycomprise refrigerant and/or pentane to enhance the thermal insulatingcharacteristics of the foam. Of course, in alternative embodiments, anyother suitable material may be used to form the components of the AHU100.

Further, each of the heat exchanger cabinet right shell 132 and the heatexchanger cabinet left shell 134 comprise an interior side surface 146,an interior rear surface 148, an exterior side surface, and an exteriorrear surface. Similarly, each of the blower cabinet right shell 136 andthe blower cabinet left shell 138 comprise an interior side surface 154,an interior rear surface 156, an exterior side surface, and an exteriorrear surface. Most generally, and with a few exceptions, each of thepairs of interior side surfaces 146, interior rear surfaces 148,exterior side surfaces, exterior rear surfaces, interior side surfaces154, interior rear surfaces 156, exterior side surfaces, and exteriorrear surfaces are substantially mirror images of each other. Morespecifically, the above listed pairs of surfaces are substantiallymirror images of each other about a bisection plane 162 (see FIG. 2)that is generally parallel to both the AHU left side 114 and the AHUright side 116 and which is substantially equidistant from both the AHUleft side 114 and the AHU right side 116.

Referring now to FIGS. 4 and 5, simplified views of the AHU 100 areprovided. Each of the heat exchanger cabinet right shell 132, the heatexchanger cabinet left shell 134, the blower cabinet right shell 136,and the blower cabinet left shell 138 comprise integral features forcarrying removable components of the AHU 100. More specifically, theinterior side surfaces 146 and interior rear surfaces 148 of the heatexchanger cabinet right shell 132 and the heat exchanger cabinet leftshell 134 comprise heater assembly mounting channels 200 bound above andbelow by heater assembly rails 202. The heater assembly rails 202protrude inwardly from the remainder of the respective interior sidesurfaces 146 and interior rear surfaces 148 so that complementary shapedstructures of the heater assembly 126 may be received within thechannels 200 and retained within the channels 200 by the heater assemblyrails 202. In this embodiment, the heater assembly 126 may beselectively inserted into the heat exchanger cabinet 104 by aligning theheater assembly 126 properly with the heater assembly mounting channels200 and sliding the heater assembly 126 toward the AHU back side 112. Ofcourse, the heater assembly 126 may be selectively removed from the heatexchanger cabinet 104 by sliding the heater assembly 126 away from theAHU back side 112. Further, one or more of the interior side surfaces146 may comprise a heater assembly shelf 204 to slidingly receive aportion of the heater assembly 126 during insertion of the heaterassembly 126 until the heater assembly 126 abuts a shelf back wall 206.

Still referring to FIGS. 4 and 5, the interior side surfaces 146 of theheat exchanger cabinet right shell 132 and the heat exchanger cabinetleft shell 134 comprise refrigeration coil assembly mounting channels208 bound above and below by refrigeration coil assembly rails 210. Therefrigeration coil assembly rails 210 protrude inwardly from theremainder of the respective interior side surfaces 146 so thatcomplementary shaped structures of the refrigeration coil assembly 128may be received within the channels 208 and retained within the channels208 by the refrigeration coil assembly rails 210. In this embodiment,the refrigeration coil assembly 128 may be selectively inserted into theheat exchanger cabinet 104 by aligning the refrigeration coil assembly128 properly with the refrigeration coil assembly mounting channels 208and sliding the refrigeration coil assembly 128 toward the AHU back side112. Of course, the refrigeration coil assembly 128 may be selectivelyremoved from the heat exchanger cabinet 104 by sliding the refrigerationcoil assembly 128 away from the AHU back side 112.

It will further be appreciated that one or more of the heat exchangercabinet right shell 132 and the heat exchanger cabinet left shell 134may comprise integrally formed electrical conduit apertures 212 whichform openings between the interior of the heat exchanger cabinet 104 andthe heat exchanger cabinet wall space. The electrical conduit apertures212 are formed and/or shaped to closely conform to the shape ofelectrical lines and/or electrical conduit that may be passed throughthe electrical conduit apertures 212. However, in some embodiments,stabilizer pads 214 may be integrally formed about the circumference ofthe electrical conduit apertures 212 so that the electrical lines and/orelectrical conduit may be more tightly held, isolated from the generalcylindrical surface of the electrical conduit apertures 212, and/or toreduce friction of insertion of electrical lines and/or electricalconduit while retaining a tight fit between the stabilizer pads 214 andthe electrical lines and/or electrical conduit. Further, the stabilizerpads 214 may be configured to interact with nuts of electrical conduitconnectors so that the stabilizer pads 214 serve to restrict rotationalmovement of such nuts. By restricting such rotational movement of nuts,the stabilizer pads 214 may provide easier assembly and/or disassemblyof the electrical conduit and related connectors to the heat exchangercabinet 104. The electrical conduit apertures 212 are not simply holesformed in the interior side surfaces 146, but rather, are substantiallytubular protrusions extending outward from the exterior side surfaces.

It will further be appreciated that one or more of the heat exchangercabinet right shell 132 and the heat exchanger cabinet left shell 134may comprise drain pan indentions 216. More specifically, the heatexchanger interior side surfaces 146 may generally comprise a slopedportion 218 sloped from a bottom side to the drain pan indentions 216 sothat the bottom of the interior side surfaces 146 protrude furtherinward and the remainder of the sloped portion 218. The drain panindentions 216 may form a concavity open toward the interior of the heatexchanger cabinet 104. The interior side surfaces 146 further comprisesa front boundary wall 220 with integral drain tubes 222 extending intothe concavity formed by the drain pan indentions 216. In someembodiments, the AHU 100 may be installed and/or operated in aninstallation orientation where the drain pan indention 216 of aninterior side surface 146 is located below the refrigeration coilassembly 128 and so that fluids may, with the assistance of gravity,aggregate within the concavity of the drain pan indention 216 andthereafter exit the AHU 100 through the integral drain tubes 222. Morespecifically, the sloped portion 218 may direct fluids falling from therefrigeration coil assembly 128 toward the concavity formed by a drainpan indention 216. In this manner, the integrally formed slope portion218, the drain pan indentions 216, and the front boundary wall 220 mayserve as a condensation drain pan for the AHU 100 and may prevent theneed to install a separate drain pan and/or to rearrange theconfiguration of a separate drain pan based on a chosen installationorientation for the AHU 100. Further, when in use, a drain pan indention216 and sloped portion 218 may cooperate with airflow generated byblower assembly 130 to direct condensation to the integral drain tubes222.

It will further be appreciated that one or more of the heat exchangercabinet right shell 132 and the heat exchanger cabinet left shell 134may comprise integral assembly recesses 224. Assembly recesses 224 maybe located near a lower end of the heat exchanger cabinet right shell132 and the heat exchanger cabinet left shell 134. Assembly recesses 224may accept mounting hardware therein for joining the heat exchangercabinet 104 to the blower cabinet 102. In this embodiment, the recesses224 are substantially shaped as box shaped recesses, however, inalternative embodiments, the recesses 224 may be shaped any othersuitable manner. Additionally, one or more of the heat exchanger cabinetright shell 132 and the heat exchanger cabinet left shell 134 maycomprise integral fastener retainer protrusions 226. Fastener retainerprotrusions 226 may be used to hold threaded nuts or other fasteners.Further, in other embodiments, retainer protrusions 226 may themselvesbe threaded or otherwise configured to selectively retaining fastenersinserted therein. Still further, the heat exchanger cabinet right shell132 and the heat exchanger cabinet left shell 134 may comprise supportbar slots 228 configured to receive the opposing ends of a selectivelyremovable structural crossbar.

Referring now to FIGS. 4 and 6, one or more of the blower cabinet rightshell 136 and the blower cabinet left shell 138 may comprise blowerassembly mounting channels 230 bound above and below by blower assemblyrails 232. The blower assembly rails 232 protrude inwardly from theremainder of the respective interior side surfaces 154 so thatcomplementary shaped structures of the blower assembly 130 may bereceived within the channels 230 and retained within the channels 230 bythe blower assembly rails 232. In this embodiment, the blower assembly130 may be selectively inserted into the blower cabinet 102 by aligningthe blower assembly 130 properly with the blower assembly mountingchannels 230 and sliding the blower assembly 130 toward the AHU backside 112. Of course, the blower assembly 130 may be selectively removedfrom the blower cabinet 102 by sliding the blower assembly 130 away fromthe AHU back side 112.

It will further be appreciated that one or more of the blower cabinetright shell 136 and the blower cabinet left shell 138 may comprisefilter mounting channels 234 bound above and below by filter rails 236.The filter rails 236 protrude inwardly from the remainder of therespective interior side surfaces 154 so that complementary shapedstructures of a filter may be received within the channels 234 andretained within the channels 234 by the filter rails 236. In thisembodiment, a filter may be selectively inserted into the blower cabinet102 by aligning the filter properly with the filter mounting channels234 and sliding the filter toward the AHU back side 112. Of course, thefilter may be selectively removed from the blower cabinet 102 by slidingthe filter away from the AHU back side 112. In some embodiments, thefilter mounting channel 234 may be sloped downward from the front to theback of the AHU 100. Further, in some embodiments, one or more of thefilter rails 236 may comprise filter protrusions 238 which may serve tomore tightly hold a filter inserted into the filter mounting channels234. In some embodiments, one or more of the blower cabinet right shell136 and the blower cabinet left shell 138 may comprise fastener retainerprotrusions 226. Still further, one or more of the blower cabinet rightshell 136 and the blower cabinet left shell 138 may comprise integralassembly recesses 240. Assembly recesses 240 may be located near anupper end of the blower cabinet right shell 136 and the blower cabinetleft shell 138. Assembly recesses 240 may accept mounting hardwaretherein for joining the blower cabinet 102 to the heat exchanger cabinet104. In this embodiment, the recesses 240 are substantially shaped asbox shaped recesses, however, in alternative embodiments, the recesses240 may be shaped in any other suitable manner.

While many of the features of the heat exchanger cabinet right shell132, heat exchanger cabinet left shell 134, blower cabinet right shell136, and blower cabinet left shell 138 may be formed integrally to thoserespective components in a single molding and/or injection process.However in alternative embodiments, the various integral features may beprovided through a series of moldings, and/or injections, thermalwelding, gluing, or any other suitable means of assembling a singularstructure comprising the various features as is well known to thoseskilled in the art. Further, one or more of the components disclosedherein as being formed integrally, in some embodiments, may be formedfrom multiple components coupled together.

Referring now to FIGS. 7-13, the blower assembly 130 is shown in greaterdetail. FIG. 7 is an oblique view of the blower assembly 130 from afront-upper-right viewpoint. FIG. 8 is an orthogonal front view of theblower assembly 130. FIG. 9 is an orthogonal rear view of the blowerassembly 130. FIG. 10 is an orthogonal top view of the blower assembly130. FIG. 11 is an orthogonal bottom view of the blower assembly 130.FIG. 12 is an orthogonal right side view of the blower assembly 130.FIG. 13 is a partial cross-sectional orthogonal right side view of theblower assembly 130. FIG. 14 is an oblique partial view of the blowerassembly 130 from a rear-upper-right viewpoint. FIG. 15 is an obliquepartial exploded view of the blower assembly 130 from a rear-lower-rightviewpoint.

The blower assembly 130 comprises a motor 300 having a shaft upon whichan impeller 304 is mounted. The motor 300 is attached to a motor mount306 that holds the motor 300 in place relative to a left shell 308 ofthe blower assembly 130 and a right shell 310 of the blower assembly130. In this embodiment, left shell 308 and the right shell 310 areselectively joined together via integral snap features as well asretaining clips 312. The snap features and the clips 312 may be operatedto optionally disconnect the left shell 308 from the right shell 310.When joined, left shell 308 and the right shell 310 may beconceptualized as defining two distinct functional portions of theblower assembled 130.

One functional portion of the blower assembly 130 may be referred to asthe blower housing 314. A primary function of the blower housing 314 isto receive at least a portion of each of the motor 300 and the impeller304 while also defining an intermediate air path between each of theleft air input port 316 of the blower assembly 130 and the right airinput port 318 of the blower assembly 130 and the blower output 320. Itis the shape of the interior of the blower housing 314 in combinationwith the movement of the impeller 304 that allows the optional intake ofair through the right air input port 318 and the left air input port 316and subsequent output of that air through the blower output 320. Anotherfunctional portion of the blower assembly 130 may be referred to as theblower deck 322. A first primary function of the blower deck 322 is toserve as a physical component used in mounting the entire blowerassembly 130 within and relative to the blower cabinet 102. A secondprimary function of the blower deck 322 is to serve as a substantial airpressure barrier between the portion of the interior of the blowercabinet 102 that houses the blower assembly 130 and the interior of, inthis embodiment, the heat exchanger cabinet 104.

Because the blower housing 314 in the blower deck 322 are substantiallyintegrally formed when the left shell 308 is joined to the right shell310, the blower housing 314 in the blower deck 322 may be conceptualizedas being joined along an interface path 324. In this embodiment,interface path 324 comprises the points at which an inner surface of theblower assembly 130 begins to primarily extend at least one of a left,right, front, and/or rear direction. Accordingly, in this embodiment,the interference path 324 generally denotes a perimeter of the bloweroutput 320.

The blower deck 322 generally comprises a left floor 326 and a rightfloor 328 that extend outward from the blower output 320 in asubstantially left, right, front, and/or rear directions so that agenerally horizontal boundary is formed. The left floor 326 extendsgenerally horizontally outward to meet a left wall 330 of the blowerdeck 322, a left portion of a front wall 332 of the blower deck 322, aleft portion of a rear wall 334 of the blower deck 322, and a left mostportion of the right floor 328. The right floor 328 extends generallyhorizontally outward to meet a right wall 336 of the blower deck 322, aright portion of the front wall 332 of the blower deck 322, a rightportion of the rear wall 334 of the blower deck 322, and a right mostportion of the left floor 326.

In this embodiment, the left floor 326 is slightly sloped so that a leftend of the left floor 326 is slightly vertically higher than a right endof the left floor 326. Similarly, in this embodiment, the right floor328 is slightly sloped so that a right end of the right floor 326 isslightly vertically higher than a left end of the right floor 328.Further, in this embodiment, a top edge of the rear wall 334 of the leftshell 308 is slightly sloped so that a right end of the top edge of therear wall 334 of the left shell 308 is slightly vertically higher than aleft end of the top edge of the rear wall 334 of the left shell 308.Similarly, in this embodiment, a top edge of the rear wall 334 of theright shell 310 is slightly sloped so that a left end of the top edge ofthe rear wall 334 of the right shell 310 is slightly vertically higherthan a right end of the top edge of the rear wall 334 of the right shell310. Still further, in this embodiment, a right end of the rear wall 334of the left shell 308 is located slightly further rearward than a leftend of the rear wall 334 of the left shell 308. Similarly, in thisembodiment, a left end of the rear wall 334 of the right shell 310 islocated slightly further rearward in a right and of the rear wall 334 ofthe right shell 310.

In this embodiment, structural webs 338 are provided to increase therigidity and/or strength of the blower assembly 130. Some structuralwebs 338 join the left wall 330 to the left floor 326 while otherstructural webs 338 join the right wall 336 to the right floor 328. Inthis embodiment, some structural webs 338 join the left floor 326 to aleft portion of the blower housing 314 while other structural webs 338join the right floor 328 to a right portion of the blower housing 314.

Referring now additionally to FIGS. 13 and 14, a drip shield 340 and amounting plate 342 are shown in greater detail. FIG. 13 is an obliquepartial view of the blower assembly 130 from an upper-rear-right inviewpoint. FIG. 14 is an oblique partial exploded view of the blowerassembly 130 from a rear-right viewpoint. FIG. 13 generally shows eachof the drip shield 340 and the mounting plate 342 in their installedpositions relative to the blower deck 322. FIG. 14 generally shows thedrip shield 340 and the mounting plate 342 together in isolation fromthe remainder of the blower assembly 130 and in exploded positionsrelative to each other so that there is a vertical offset distancebetween the two.

The drip shield 340 comprises a generally horizontal cover comprising abent plate 344 having a central ridge 346 extending in aforward-rearward direction and from such ridge 346 the bent plate 344extends both in the left direction in the right direction. As the bentplate 344 extends from the ridge 346 in the left direction, the bentplate 344 extends slightly downward from the vertical height of theridge 346. Similarly, as the bent plate 344 extends from the ridge 346in the right direction, the bent plate 344 extends slightly downwardfrom the vertical height of the ridge 346. In this embodiment, it willbe appreciated that the underside of the bent plate 344 is dimensionedto complement and accordingly to optionally mate with the upper end ofthe front wall 332 of the blower deck 322. As shown, a rear left cornerof the bent plate 344 and a rear right corner of the bent plate 344 areeach locally bent vertically downward. Accordingly, when installedand/or attached to the blower deck 322, water and/or condensation thatcontacts the bent plate 344 from above may tend to drain downward andaway from any electrical components carried by the mounting plate 342.In some embodiments, water and/or condensation may be routed by the bentplate 344 toward left floor 326 and the right floor 328 rather thanpooling above any electrical components carried by the mounting plate342.

In this embodiment, the bent plate 344 further comprises a left tab 348,a right tab 350, and front tabs 352. The left tab 348 extends generallydownward from the left side of the bent plate 344. The right tab 350extends generally downward from the right side of the bent plate 344.The front tabs 352 extend generally upward from the front side of thebent plate 344.

This embodiment, the mounting plate 342 comprises a generally verticalcomponent wall 354 configured for mounting against the front wall 332 ofthe blower deck 322. Mounting plate 342 further comprises forward tabsthat extend generally forward from an upper end of the component wall354. The upper end of the mounting plate 342 and the forward tabs 356are configured to complement the underside of the bent plate 344 and tomate against the underside of the bent plate 344.

Referring now to FIG. 2, it can be seen that when the blower assembly130 is installed into the blower cabinet 102, the blower deck 322generally provides a zone boundary 358 between a first interior zone 360of the AHU 100 and a second interior zone 362 of the AHU 100. The firstinterior zone 360 is generally associated with the left and right airinput ports 316, 318 of the blower assembly 130 while the secondinterior zone 362 is generally associated with a space adjacent theblower output 320 and which, in this embodiment, is generally associatedwith the coil assembly 128. More specifically, in this embodiment, theleft and right floors 326, 328 of the blower deck 322 generally dividethe interior of the AHU 100 into the first and second interior zones360, 362 so that operation of the motor 300 to rotate the impeller 304may cause a pressure differential between the zones 360, 362.

In this embodiment, the blower deck 322 does not provide the entire zoneboundary 358, but rather, the zone boundary 358 is at least partiallydefined by the drip shield 340. More specifically, in this embodiment,the zone boundary 358 comprises the left floor 326, the right floor 328,and the bent plate 344. Of course in other embodiments, the blower deck322 may be configured to incorporate the functionality of the dripshield into the blower deck 322 itself as a unitary component.Nonetheless, this disclosure provides a blower assembly 130 thatcomprises components that form an entire zone boundary 358 when theblower assembly 130 is installed into the AHU 100.

More particularly, when the blower assembly 130 is installed into theAHU 100, the following components may be mated and/or located adjacenteach other to produce the zone boundary 358: the rear wall 334 and theinterior rear surface 156 and/or mounting channels 230, the right wall336 and the right interior side surfaces 154 and/or mounting channels230, the left wall 330 and the left interior side surfaces 154 and/ormounting channels 230, the upper end of the front wall 332 and theunderside of the bent plate 344 of the drip shield 340, the front tabs352 of the drip shield 340 and the back side of the blower cabinet panel120, the left tab 348 of the drip shield 340 and the left interior sidesurface 154 and/or mounting channels 230, and the right tab 350 of thedrip shield 340 and the right interior side surface 154 and/or mountingchannels 230.

In some embodiments, a center of mass and/or a center of gravity of theblower assembly 130 is located within a periphery the components thatform the zone boundary 358, as viewed from above. In some cases, bylocating the center of mass and/or center of gravity in the abovedescribed manner may allow better distribution of forces due to gravityalong a greater footprint so that gravitational forces do notconsistently produce large bending moments against a blower deck that isnot integral to a blower assembly.

At least one embodiment is disclosed and variations, combinations,and/or modifications of the embodiment(s) and/or features of theembodiment(s) made by a person having ordinary skill in the art arewithin the scope of the disclosure. Alternative embodiments that resultfrom combining, integrating, and/or omitting features of theembodiment(s) are also within the scope of the disclosure. Wherenumerical ranges or limitations are expressly stated, such expressranges or limitations should be understood to include iterative rangesor limitations of like magnitude falling within the expressly statedranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4,etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example,whenever a numerical range with a lower limit, RI, and an upper limit,Ru, is disclosed, any number falling within the range is specificallydisclosed. In particular, the following numbers within the range arespecifically disclosed: R=RI+k*(Ru−RI), wherein k is a variable rangingfrom 1 percent to 100 percent with a 1 percent increment, i.e., k is 1percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent,51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98percent, 99 percent, or 100 percent. Moreover, any numerical rangedefined by two R numbers as defined in the above is also specificallydisclosed. Use of the term “optionally” with respect to any element of aclaim means that the element is required, or alternatively, the elementis not required, both alternatives being within the scope of the claim.Use of broader terms such as comprises, includes, and having should beunderstood to provide support for narrower terms such as consisting of,consisting essentially of, and comprised substantially of. Accordingly,the scope of protection is not limited by the description set out abovebut is defined by the claims that follow, that scope including allequivalents of the subject matter of the claims. Each and every claim isincorporated as further disclosure into the specification and the claimsare embodiment(s) of the present invention.

1. An air handling unit, comprising: a blower assembly; a first interiorzone; and a second interior zone; wherein the blower assembly physicallyseparates the first interior zone from the second interior zone.
 2. Theair handling unit of claim 1, wherein the first interior zone isassociated with an input to a blower housing of the blower assembly. 3.The air handling unit of claim 2, wherein the second interior zone isassociated with a blower output of the blower housing.
 4. The airhandling unit of claim 3, wherein a pressure differential between thefirst interior zone and the second interior zone is primarilyattributable to a zone boundary between the first interior zone and thesecond interior zone provided by a blower deck of the blower assembly.5. The air handling unit of claim 4, wherein the blower deck is formedintegrally with the blower housing and wherein the blower housing housesat least a portion of a motor of the blower assembly and an impeller ofthe blower assembly.
 6. The air handling unit of claim 4, whereinsubstantially the entire zone boundary is formed by components of theblower assembly.
 7. The air handling unit of claim 6, wherein at leastone of the components forming the zone boundary are sloped to manage aflow of water away from an electrical component of the blower assembly.8. The air handling unit of claim 1, wherein the blower deck extendssubstantially an entire distance from a left interior wall of a blowercabinet of the air handling unit to an opposite right interior wall ofthe blower cabinet.
 9. The air handling unit of claim 8, wherein theblower deck extends from a blower outlet to a rear interior wall of theair handling unit.
 10. The air handling unit of claim 9, wherein theblower deck extends from the blower outlet to a front panel of theblower cabinet.
 11. A method of creating air pressure zones in an airhandling unit, comprising: providing a cabinet configured to receive ablower assembly; inserting a blower assembly into the air duct; andclosing a cabinet door of the cabinet; wherein upon closing the cabinetdoor, the primary air flow path from a location within the cabinetdownstream of the blower assembly to a location within the cabinetupstream of the blower assembly is through a blower housing of theblower assembly.
 12. The method of claim 11, further comprising:blocking air flow around the primary air flow path by spanning a blowerdeck of the blower assembly between the interior walls of the cabinet.13. The method of claim 11, wherein the blower assembly comprises ablower deck extending between at least two opposing interior walls ofthe cabinet.
 14. The method of claim 13, further comprising: sliding theblower deck into integral mounting channels of the at least two opposinginterior walls of the cabinet.
 15. The method of claim 14, furthercomprising: sliding the blower deck into a third mounting channel of theinterior walls of the cabinet.
 16. A blower assembly for an air handlingunit of an HVAC system, the blower assembly comprising: a blower housingcomprising at least one air inlet and at least one air outlet; and ablower deck extending from the outlet, wherein the blower deck comprisesat least one substantially flat component having a substantiallyorthogonal wall extending from the flat component.
 17. The blowerassembly of claim 16, wherein the wall is located along an edge of theflat component.
 18. The blower assembly of claim 17, wherein astructural web extends between the wall and the flat component.
 19. Theblower assembly of claim 17, wherein a structural web extends betweenthe flat component and the blower housing.
 20. The blower assembly ofclaim 16, wherein the blower assembly comprises a first shell mated to asecond shell and wherein the first shell comprises a portion of each ofthe blower housing and the blower deck and wherein the second shellcomprises a portion of each of the blower housing and the blower deck.